Concepts of Lean Manufacturing and Six Sigma

Course Description

This course provides an introduction to the fundamental principles and theories of Lean Manufacturing and Six Sigma as applied in manufacturing and service industries. Lean Manufacturing involves identifying and eliminating non-value-adding activities in design, production, and supply chain management. The course also presents a comprehensive overview of the Six Sigma methodology, including the Define, Measure, Analyze, Improve, and Control (DMAIC) process improvement paradigm rooted in the Toyota Production System model of business operations. Students develop practical skills in waste reduction, quality improvement, and process optimization aligned with industry standards recognized by the American Society for Quality (ASQ) and the Council for Six Sigma Certification.

This is a combined lecture/laboratory course (ETI2622C) within the Engineering Technologies — Industrial Systems Technology taxonomy of the Florida Statewide Course Numbering System (SCNS).

Learning Outcomes

Required Outcomes

Upon successful completion of this course, students will be able to:

• Explain the core principles of Lean Manufacturing and their origin in the Toyota Production System.
• Identify and classify the eight types of waste (muda) present in manufacturing and service processes.
• Apply the 5S methodology (Sort, Set in Order, Shine, Standardize, Sustain) to organize and improve a workplace or production environment.
• Construct and interpret a Value Stream Map (VSM) to identify non-value-adding activities and improvement opportunities.
• Describe the DMAIC (Define, Measure, Analyze, Improve, Control) framework and apply it to a structured process improvement problem.
• Explain the concept of continuous flow and differentiate it from traditional batch-and-queue production.
• Define Kaizen and describe its role in sustaining a culture of continuous improvement.
• Calculate and interpret Overall Equipment Effectiveness (OEE) as a measure of production efficiency.
• Explain the Six Sigma philosophy as a data-driven, defect-prevention approach to quality and process improvement.
• Identify the Six Sigma belt structure (Yellow Belt, Green Belt, Black Belt, Master Black Belt) and the roles associated with each level.

Optional Outcomes

Depending on instructor emphasis and available laboratory resources, students may also:

• Apply basic statistical process control (SPC) tools, including control charts, Pareto charts, and cause-and-effect (Ishikawa) diagrams.
• Use process mapping and SIPOC diagrams to document and analyze process inputs and outputs.
• Demonstrate the use of Minitab or equivalent statistical software for process data analysis.
• Conduct a structured root cause analysis using the 5-Why method and fishbone diagrams.
• Complete a simulated or real-world Lean Six Sigma improvement project using the DMAIC framework.
• Discuss the application of Design for Manufacturing (DFM) and its relationship to Lean principles.

Major Topics

Required Topics

The following content areas are covered consistently across Florida college offerings of this course:

• Introduction to Lean Manufacturing — history, philosophy, and the Toyota Production System
• Identification and Elimination of Waste (Muda) — the eight wastes: transportation, inventory, motion, waiting, overproduction, overprocessing, defects, and underutilized talent
• 5S Workplace Organization — Sort, Set in Order, Shine, Standardize, Sustain; visual management techniques
• Value Stream Mapping (VSM) — current-state and future-state mapping; identifying value-added vs. non-value-added steps
• Continuous Flow and Pull Systems — one-piece flow, Kanban systems, takt time calculation
• Kaizen and Continuous Improvement — rapid improvement events, team-based problem solving
• Overall Equipment Effectiveness (OEE) — availability, performance, and quality metrics
• Introduction to Six Sigma — philosophy, history (Motorola origins), and quality standards
• DMAIC Process Improvement Paradigm — Define, Measure, Analyze, Improve, Control phases in detail
• Six Sigma Belt Structure and Project Roles — organizational roles and responsibilities
• Basic Quality Tools — Pareto charts, fishbone/Ishikawa diagrams, control charts, histograms, scatter diagrams, check sheets, run charts
• Modular and Cellular Manufacturing — work cell design, layout optimization
• Total Productive Maintenance (TPM) — preventive and predictive maintenance strategies

Optional Topics

Topics covered at the discretion of the instructor or institution:

• Statistical Process Control (SPC) — control chart types, process capability indices (Cp, Cpk)
• Design for Manufacturing and Assembly (DFMA)
• Lean in Service Industries — application of Lean and Six Sigma beyond manufacturing (healthcare, banking, logistics)
• SIPOC Diagrams and Process Mapping — Suppliers, Inputs, Process, Outputs, Customers
• Root Cause Analysis — 5-Why analysis, fault tree analysis
• Introduction to Minitab or Statistical Software — basic data entry, graphing, and analysis
• Self-Directed Work Teams — team dynamics, leadership, and change management in continuous improvement
• Green Lean Six Sigma — environmental sustainability integration with Lean and Six Sigma principles

Resources & Tools

• Textbook: Lean Six Sigma by Donna C.S. Summers (commonly adopted at Florida colleges including Chipola College)
• Reference: The Lean Six Sigma Pocket Toolbook by George, Rowlands, Price & Maxey (recommended at FAU)
• Software: Minitab statistical software (used for data analysis and SPC exercises where applicable); Microsoft Excel for data collection and charting
• Standards & Frameworks: American Society for Quality (ASQ) Body of Knowledge; Council for Six Sigma Certification (CSSC) standards
• Laboratory/Simulation: Hands-on Lean simulation exercises (e.g., assembly simulation games illustrating batch vs. flow production)

Career Pathways

Graduates who complete this course and associated Industrial Systems Technology program requirements are prepared for roles such as:

• Continuous Improvement Specialist
• Manufacturing / Process Engineer
• Quality Control Technician
• Production Supervisor
• Industrial Engineering Technician
• Lean Coordinator / Lean Practitioner
• Operations Analyst
• Supply Chain / Logistics Coordinator

Professionals with Lean and Six Sigma skills remain in high demand across industries — including aerospace, automotive, healthcare, and logistics — as businesses seek to improve competitive and strategic opportunities.

Special Information

Certification Preparation

This course is designed to provide foundational preparation toward nationally recognized Lean Six Sigma certifications. Completion supports readiness for the following credentials:

• Lean Six Sigma Yellow Belt — entry-level certification attainable upon mastery of course content (Council for Six Sigma Certification or ASQ)
• Lean Six Sigma Green Belt — advanced certification; this course typically serves as the first course in a multi-course Green Belt College Credit Certificate sequence (e.g., as offered at St. Petersburg College and College of Central Florida)
• ASQ Certified Quality Improvement Associate (CQIA) — complementary entry-level quality certification

The College of Central Florida is a registered training provider for the Council for Six Sigma Certification. Students interested in pursuing ASQ Green Belt exam preparation should consult their institution's workforce development division for supplementary exam prep resources. FAU's Six Sigma programs are aligned with ASQ, IASSC, ISSSP, and The Council for Six Sigma Certification standards.

Note: The “C” suffix in ETI2622C denotes a combined lecture and laboratory course under the Florida SCNS. Students should expect both classroom instruction and hands-on lab or simulation activities as integral parts of the course requirements.